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Cat RH340B, (6060 FS) Hydraulic Shovel Operation and Maintenance Manual EM029199 – PDF DOWNLOAD
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Description
Cat RH340B, (6060 FS) Hydraulic Shovel Operation and Maintenance Manual EM029199 – PDF DOWNLOAD
FILE DETAILS:
Cat RH340B (6060 FS) Hydraulic Shovel Operation and Maintenance Manual EM029199 – PDF DOWNLOAD
Language : English
Pages : 338
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Cat RH340B (6060 FS) Hydraulic Shovel Operation and Maintenance Manual EM029199 – PDF DOWNLOAD
OPERATING INSTRUCTIONS RH340B
Introduction
Introduction
PREFACE
- These operating instructions are designed to familiarize the operator with the machine and its designated use. The operating instructions contain important information on how to operate the machine safely, properly and with maximum efficiency.
- Observing these instructions helps to prevent hazardous situations, to reduce repair costs and downtimes and to increase the reliability and service life of the machine. The operating instructions must be supplemented by the respective national rules and regulations for accident prevention and environmental protection.
- The operating instructions must always be available in the driver’s cab of the machine. The operating instructions must be read and put into practice by any person in charge of carrying out work with or on the machine, such as
operation, including setting-up, troubleshooting in the course of work, care, evacuation of production waste and disposal of fuels and consumables,
maintenance (inspection, servicing, repair) and / or
transport
- In addition to the operating instructions and the mandatory rules and regulations for accident prevention and environmental protection in the user’s country and at the place where the machine is to be used, the generally recognized technical rules for safe and proper working must be observed 1 The operating instructions are directed to the construction- machine specialist. They cannot provide basic know-how.
- This can be acquired, for example, in several days’ instruction by a qualified Bucyrus HEX mechanic or by attending an Bucyrus HEX training course for operators or maintenance personnel. The Bucyrus HEX after-sales service will be pleased to deal with any queries you may have after reading through the operating instructions.
- 1 Complies with VDMA recommendation “Operating instructions” All Bucyrus HEX operating manuals are issued in German and then translated. Even a good translation may give rise to questions which Bucyrus HEX will be pleased to answer. The operating instructions are not work instructions for carrying out major repairs. Such work is willingly done for you by the Bucyrus HEX aftersales service.
- The documentation relating to the machine is listed according to scope, quantity and language in the shipping note of the machine or in the covering letter if supplied separately. The operating instructions and spare-parts list are marked with the serial number of the machine. On taking receipt of the consignment, please check that the documentation is complete and in the language requested by you.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Cat RH340B (6060 FS) Hydraulic Shovel Operation and Maintenance Manual EM029199 – PDF DOWNLOAD
01_operating_RH340B_3725045_00_EN................................................................................................................................................ 3 1 INTRODUCTION............................................................................................................................................................... 13 PREFACE ................................................................................................................................................................. 15 WARRANTY ................................................................................................................................................................ 16 FUNDAMENTAL SAFETY INSTRUCTIONS.......................................................................................................................................... 17 Warnings and symbols................................................................................................................................................. 17 DESIGNATED USE........................................................................................................................................................... 18 ORGANIZATIONAL MEASURES.................................................................................................................................................. 19 Selection and qualification of personnel; basic responsibilities..................................................................................................... 20 Safety instructions governing specific operational phases............................................................................................................ 20 Special work in conjunction with utilization of the machine and maintenance and repairs as well as troubleshooting during work; disposal of parts and consumables.... 21 Warning of special dangers........................................................................................................................................... 22 Hydraulic equipment.................................................................................................................................................. 23 Transporting and recommissioning..................................................................................................................................... 23 FIRE AND EXPLOSION HAZARD................................................................................................................................................ 24 NOTES ................................................................................................................................................................... 25 2 OPERATION.................................................................................................................................................................. 27 OPERATION - SAFETY INSTRUCTIONS.......................................................................................................................................... 29 Operating Instructions, where to store it in the driver’s cab ....................................................................................................... 30 OPERATION, FIRE AND EXPLOSION HAZARD..................................................................................................................................... 31 DESCRIPTION OF THE EXCAVATOR............................................................................................................................................. 32 Excavator layout .................................................................................................................................................... 33 Undercarriage ....................................................................................................................................................... 34 Superstructure....................................................................................................................................................... 34 Drive................................................................................................................................................................ 34 Hydraulic system..................................................................................................................................................... 34 Pump Managing System (PMS)........................................................................................................................................... 34 Programmable Logic Controller (PLC) ................................................................................................................................. 34 Control Management System (CMS) ..................................................................................................................................... 34 Demand control / Zero-flow regulation................................................................................................................................ 35 Automatic engine speed reduction .................................................................................................................................... 35 Board-Control-System (BCS) .......................................................................................................................................... 35 Electrical system ................................................................................................................................................... 35 Signs ............................................................................................................................................................... 37 Entering and leaving the machine, Safety instructions ............................................................................................................... 38 Access ladder lighting, switching on / off .......................................................................................................................... 38 Folding ladder (optional) ........................................................................................................................................... 39 Swinging ladder (optional) .......................................................................................................................................... 40 Escape ladder ....................................................................................................................................................... 41 Cab interior lighting, switching on / off .......................................................................................................................... 42 Illuminating the control column ..................................................................................................................................... 43 Maintenance lights, switching on / off .............................................................................................................................. 44 EMERGENCY STOP pushbuttons .......................................................................................................................................... 45 Driver’s seat ...................................................................................................................................................... 46 Trainer's / instructor's seat ....................................................................................................................................... 48 Windscreen washer ................................................................................................................................................... 48 Fire extinguisher ................................................................................................................................................... 49 Automatic fire-extinguishing system (optional)....................................................................................................................... 50 Harness (optional)................................................................................................................................................... 51 MONITORING, WARNING AND CONTROL ELEMENTS ................................................................................................................................ 54 PUTTING THE MACHINE INTO OPERATION ...................................................................................................................................... 88 Refuelling .......................................................................................................................................................... 88 Service station (tanklift) .......................................................................................................................................... 88 Back-up heating (option), filling in fuel ........................................................................................................................... 90 Switching the electrical system on and off .......................................................................................................................... 94 Preheating system for engine and hydraulic oil (optional) ........................................................................................................... 95 Fuel preheating system (optional) ................................................................................................................................... 96 STARTING AND STOPPING THE ENGINES ....................................................................................................................................... 97 Starting the engines at low temperatures ............................................................................................................................ 98 Shutting off the engines ............................................................................................................................................ 99 Emergency - stop .................................................................................................................................................... 99 AIR CONDITIONER (OPTION).................................................................................................................................................100 Back-up heating (option) ............................................................................................................................................101 Back-up heating driver’s cab (option) ...............................................................................................................................102 DRIVING .................................................................................................................................................................103 SAFETY INSTRUCTIONS .................................................................................................................................................103 Superstructure basic position .......................................................................................................................................104 Emergency machine drive .............................................................................................................................................108 Locking the superstructure ..........................................................................................................................................110 Track parking brake .................................................................................................................................................110 TRANSPORTING THE MACHINE ................................................................................................................................................111 Safety instructions .................................................................................................................................................111 WORKING OPERATION .......................................................................................................................................................112 Safety instructions .................................................................................................................................................112 Running-in instructions for hydraulic cylinders .....................................................................................................................112 Warming up ..........................................................................................................................................................112 Avoid extreme positions of the working equipment ....................................................................................................................113 Before starting work ................................................................................................................................................114 Swinging the superstructure .........................................................................................................................................114 Braking the superstructure ..........................................................................................................................................114 Working operation ...................................................................................................................................................115 After daily operation ...............................................................................................................................................116 ASSEMBLING WORKING EQUIPMENT ............................................................................................................................................117 SAFETY INSTRUCTIONS .................................................................................................................................................117 Securing the machine ................................................................................................................................................119 CORROSION PROTECTION FOR PINS AND BEARINGS (BUSHINGS AND HUBS) ..........................................................................................................120 NOTES ...................................................................................................................................................................121 3 INSPECTION AND SERVICING...................................................................................................................................................123 INSPECTION AND SERVICING - SAFETY INSTRUCTIONS ..........................................................................................................................125 INSPECTION AND SERVICING WORK, FIRE AND EXPLOSION HAZARD ................................................................................................................131 INSPECTION AND SERVICING PLANS - INSTRUCTIONS ...........................................................................................................................133 Intervals............................................................................................................................................................133 Change of engine oil ................................................................................................................................................133 Air-intake system ...................................................................................................................................................133 Oils / Greases ......................................................................................................................................................133 Cleaning jobs .......................................................................................................................................................133 Components ..........................................................................................................................................................133 Plan V ..............................................................................................................................................................135 Plan N ..............................................................................................................................................................137 Plan T and W ........................................................................................................................................................139 Plan A – E ..........................................................................................................................................................141 LUBRICATING CHART .......................................................................................................................................................148 Lubricating chart – Grease (legend) .................................................................................................................................149 Filling quantities - Grease..........................................................................................................................................149 INSPECTION PLAN - OIL ...................................................................................................................................................150 Inspection plan – Oil (legend) ......................................................................................................................................151 Filling quantities - oil ............................................................................................................................................152 Filling quantities - other...........................................................................................................................................152 LUBRICANTS ..............................................................................................................................................................153 Notes on the selection of oils and greases ..........................................................................................................................153 Avoid mixing of different hydraulic fluids ..........................................................................................................................153 I. Oil for combustion engines and compressors .......................................................................................................................154 II. Oil for hydraulic system ........................................................................................................................................155 III.a Oil for pump distribution gearboxes ...........................................................................................................................156 III.b Oil for swing gearboxes .......................................................................................................................................157 III.c Oil for travel gearboxes ......................................................................................................................................158 V. Greases for bearings and swing rings .............................................................................................................................159 SERVICING WORK ..........................................................................................................................................................160 Hose line for oil and cooling liquid changes ........................................................................................................................160 ENGINE ..................................................................................................................................................................161 Engine - Safety instructions ........................................................................................................................................161 Checking the engine oil level / Topping up .........................................................................................................................162 Changing the engine oil .............................................................................................................................................163 Replacing the oil filter ............................................................................................................................................165 Cold-starting fluid (ether) - Replacing the pressure vessel .........................................................................................................166 COOLING SYSTEM ..........................................................................................................................................................167 Radiators ...........................................................................................................................................................168 Cooling liquid, change ..............................................................................................................................................170 AIR-INTAKE SYSTEM .......................................................................................................................................................171 Dust trap, cleaning ................................................................................................................................................171 Main filter elements ................................................................................................................................................172 Safety filter element ...............................................................................................................................................174 Air-intake lines ....................................................................................................................................................174 FUEL SYSTEM .............................................................................................................................................................175 Fuel system - Safety instructions ...................................................................................................................................175 Replacing the fuel filter ...........................................................................................................................................175 Venting the fuel system .............................................................................................................................................176 Cleaning the fuel tanks .............................................................................................................................................176 Water trap (option) .................................................................................................................................................178 ELECTRICAL SYSTEM ......................................................................................................................................................180 Electrical system - Safety instructions .............................................................................................................................180 Alternator - Instructions ...........................................................................................................................................180 Battery .............................................................................................................................................................181 Switchgear cabinet ..................................................................................................................................................183 Floodlight projector, replacing the lamp ............................................................................................................................185 HYDRAULIC SYSTEM ........................................................................................................................................................187 Hydraulic system - Safety instructions ..............................................................................................................................187 Depressurizing the hydraulic system .................................................................................................................................187 Checking the hydraulic oil level ....................................................................................................................................188 Changing the hydraulic oil return-flow filters (hydraulic oil reservoir) ............................................................................................190 Bypass valves (hydraulic oil reservoir) .............................................................................................................................192 Hydraulic reservoir, breather filter ................................................................................................................................193 Filter (control circuit), change.....................................................................................................................................194 High-pressure filter for working hydraulics .........................................................................................................................195 High-pressure filters for the servo circuit .........................................................................................................................196 High-pressure filters for feeding circuits and swing pumps ..........................................................................................................197 High-pressure filters for swing circuit .............................................................................................................................198 Changing the hydraulic oil ..........................................................................................................................................199 Avoid mixing of different hydraulic fluids ..........................................................................................................................199 Venting the hydraulic system.........................................................................................................................................203 Cleaning the hydraulic oil cooler ...................................................................................................................................204 Electronic excavator control ........................................................................................................................................205 Pressure accumulator - Emergency lowering............................................................................................................................206 PUMP TRANSFER GEARBOX ...................................................................................................................................................207 Gearbox oil level / checking, topping up with oil ...................................................................................................................207 Gearbox pre-chamber oil level / checking, topping up with oil .......................................................................................................208 Changing the gearbox oil ............................................................................................................................................209 Changing the gearbox oil, pre-chamber ...............................................................................................................................210 Gearbox venting .....................................................................................................................................................210 Gearbox venting, pre-chamber ........................................................................................................................................211 Pump transfer gearbox lube oil filters ..............................................................................................................................212 SWING GEARBOX ...........................................................................................................................................................213 Swing gearbox, checking the oil level / topping up with oil .........................................................................................................213 Swing gearbox oil, change ...........................................................................................................................................213 Swing gearbox, venting ..............................................................................................................................................214 TRAVEL GEARBOX ..........................................................................................................................................................215 Travel gearbox - Checking the oil level / Topping up with oil .......................................................................................................215 Travel gearbox - Changing oil .......................................................................................................................................216 Travel gearbox pre-chamber - Changing the oil .......................................................................................................................216 Travel gearbox brake chamber - Changing oil .........................................................................................................................217 Travel gearbox breather filter ......................................................................................................................................217 CRAWLER TRACKS ..........................................................................................................................................................218 Track rollers,grease ................................................................................................................................................219 Track tensioner .....................................................................................................................................................220 Pressure-accumulator inspection regulations .........................................................................................................................221 Checking the gas charging pressure in the pressure accumulator.......................................................................................................221 SWING RING ..............................................................................................................................................................222 Swing ring - Instructions............................................................................................................................................222 Bearing races........................................................................................................................................................222 CENTRAL LUBRICATING .....................................................................................................................................................224 Design ..............................................................................................................................................................224 Function ............................................................................................................................................................225 Filling up the grease container .....................................................................................................................................226 Breather filter .....................................................................................................................................................226 Checking the greasing pressure ......................................................................................................................................227 Checking the greasing pressure ......................................................................................................................................228 Unblocking a grease line ............................................................................................................................................229 Unblocking a grease line ............................................................................................................................................229 Oilfilter (hydraulic circuit grease pump) ...........................................................................................................................230 Grease filter (Filling the grease container) ........................................................................................................................231 Grease filter (Grease lines) ........................................................................................................................................232 OTHER MAINTENANCE .......................................................................................................................................................233 Equipment check .....................................................................................................................................................234 HYDRAULIC LADDER ........................................................................................................................................................235 Pressure-accumulator inspection regulations ........................................................................................................................236 Checking the gas charging pressure in the pressure accumulator ......................................................................................................236 ON-BOARD CRANE (OPTIONAL) ...............................................................................................................................................237 On-board crane, monitoring, warning and control elements ............................................................................................................237 On-board crane, checking ............................................................................................................................................237 On-board crane, drive unit ..........................................................................................................................................238 On-board crane, servicing ...........................................................................................................................................238 On-Board crane, checking tightness of fastening bolts ...............................................................................................................239 PUTTING THE EXCAVATOR OUT OF OPERATION AND RECOMMISSIONING ..............................................................................................................240 Putting the excavator out of operation...............................................................................................................................240 Battery storage .....................................................................................................................................................240 Recommissioning .....................................................................................................................................................240 NOTES ...................................................................................................................................................................241 4 REPAIR WORK................................................................................................................................................................243 REPAIR WORK - SAFETY INSTRUCTIONS........................................................................................................................................245 REPAIR WORK, FIRE AND EXPLOSION HAZARD ..................................................................................................................................247 REPAIR WORK, ENGINE......................................................................................................................................................248 ELECTRICAL SYSTEM .......................................................................................................................................................249 Assisted starting (with jumper cables) – Safety instructions ........................................................................................................249 Assisted starting (with jumper cables)...............................................................................................................................249 Starting the engine with jumper cables (external batteries ..........................................................................................................249 HYDRAULIC SYSTEM; REPAIR INSTRUCTIONS ...................................................................................................................................251 Hydraulic hoses – Instructions .....................................................................................................................................251 PRESSURE ACCUMULATORS - SAFETY INSTRUCTIONS..............................................................................................................................252 WELDING OPERATIONS - SAFETY INSTRUCTIONS ................................................................................................................................253 NOTES ...................................................................................................................................................................255 5 ANNEX......................................................................................................................................................................257 TROUBLESHOOTING .........................................................................................................................................................259 Instructions on troubleshooting .....................................................................................................................................259 Layout of the fault table ...........................................................................................................................................259 Possible causes .....................................................................................................................................................259 Measures ............................................................................................................................................................259 Section .............................................................................................................................................................259 FAULT TABLES ............................................................................................................................................................260 Combustion engine - Fault table .....................................................................................................................................260 Working hydraulics – Fault table ....................................................................................................................................261 Track drive – Fault table ...........................................................................................................................................262 Swing mechnism – Fault table ........................................................................................................................................263 Central lubricating system – Fault table ............................................................................................................................264 HYDRAULIC CIRCUIT DIAGRAM ...............................................................................................................................................265 ABBREVIATIONS ...........................................................................................................................................................267 ABBREVIATIONS ...........................................................................................................................................................268 TECHNICAL DATA ..........................................................................................................................................................269 Datasheet_RH340B..................................................................................................................................................... 0 RH340B__DataSheet_english_1......................................................................................................................................271 RH340B__DataSheet_english_2......................................................................................................................................272 RH340B__DataSheet_english_3......................................................................................................................................273 RH340B__DataSheet_english_4......................................................................................................................................274 RH340B__DataSheet_english_5......................................................................................................................................275 RH340B__DataSheet_english_6......................................................................................................................................276 RH340B__DataSheet_english_7......................................................................................................................................277 RH340B__DataSheet_english_8......................................................................................................................................278 NOTES ...................................................................................................................................................................279 6 INDEX......................................................................................................................................................................281 02_operating_BCS_RH340B_3725017_EN...............................................................................................................................................287 Operating Instructions BCS...................................................................................................................................................287 DESCRIPTION .............................................................................................................................................................291 Functions ...........................................................................................................................................................291 Components ..........................................................................................................................................................291 DISPLAYS : USING BCS.....................................................................................................................................................292 Display and keyboard ................................................................................................................................................294 Indicator lights ................................................................................................................................................295 Buttons .........................................................................................................................................................295 Instruments .........................................................................................................................................................296 Service menu ........................................................................................................................................................296 Program 1: Oil change ...........................................................................................................................................297 Program 2 to 6 ..................................................................................................................................................297 The programs (Fig. 15)...........................................................................................................................................297 Program 2: Service ..............................................................................................................................................297 Program 3: Engine ...............................................................................................................................................298 Program 4: Hydraulics (Fig. 19)..................................................................................................................................298 Program 5: Excavator ...........................................................................................................................................299 Program 6: Operating hours ......................................................................................................................................299 HOLD function ...................................................................................................................................................300 IMPORTANT........................................................................................................................................................300 Program 7: Setting date and time ................................................................................................................................301 Program 8: Complete fault list ..................................................................................................................................302 Program 9: Service Bucyrus HEX ..................................................................................................................................302 Fault reports ...................................................................................................................................................303 Service data & fault storage: print-out or transfer into Buffer .....................................................................................................304 APPENDIX ................................................................................................................................................................305 Print-out ...........................................................................................................................................................305 DATA ACQUISITION COMPUTER DER 1..........................................................................................................................................307 Sensor analogue inputs...............................................................................................................................................307 DATA ACQUISITION COMPUTER DER 1..........................................................................................................................................308 Sensor digital inputs................................................................................................................................................308 DATA ACQUISITION COMPUTER DER 2..........................................................................................................................................309 Sensor analogue inputs...............................................................................................................................................309 DATA ACQUISITION COMPUTER DER 2..........................................................................................................................................310 Sensor digital inputs................................................................................................................................................310 DATA ACQUISITION COMPUTER DER 3..........................................................................................................................................311 Sensor analogue inputs...............................................................................................................................................311 DATA ACQUISITION COMPUTER DER 3..........................................................................................................................................312 Sensor digital inputs................................................................................................................................................312 03_oilsamples_oilanalysis_3725027en..............................................................................................................................................315 Technical Handbook, titlepage................................................................................................................................................315 Safety instructions .....................................................................................................................................................319 Notes on the selection of oils and greases ..............................................................................................................................319 Original Bucyrus HEX oils and greases....................................................................................................................................319 Alternative oils and greases.............................................................................................................................................319 Why carry out oil analyses? .............................................................................................................................................320 Prerequisites for valid oil samples .....................................................................................................................................321 Analyses-Sets........................................................................................................................................................321 Taking oil samples ......................................................................................................................................................322 Sampling from assemblies equipped with sampling valve................................................................................................................322 Sampling from assemblies without sampling valve .....................................................................................................................323 Interpreting the results of the oil analysis ............................................................................................................................324 A typical laboratory report .........................................................................................................................................324 Typical laboratory report ...........................................................................................................................................325 Typical wear limits .....................................................................................................................................................326 For hydraulic oil in the RH40E, RH 70, RH90C, RH120E, RH170 machines ................................................................................................327 For hydraulic oil in RH200, RH340, RH400 machines ...................................................................................................................328 For oil in the pump transfer gearboxes of the RH40E, RH70, RH90C, RH120E ............................................................................................329 For oil in the pump transfer gearboxes of the RH170, RH200, RH340 ...................................................................................................330 For oil in the pump transfer gearboxes of the RH400 .................................................................................................................331 For oil in the swing gearboxes of the RH40E - RH400 .................................................................................................................332 For oil in the travel gearboxes of the RH40E, RH70, RH90C ..........................................................................................................333 For oil in the travel gearboxes of the RH120E, RH170, RH340 ........................................................................................................334 For oil in the travel gearboxes of the RH200, RH400 .................................................................................................................335 Notes ...................................................................................................................................................................336
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